Galil DMC-1800 User manual

Brand: Galil

Model: DMC-1800

Category: Bridge cameras

Type: User manual

This manual is also suitable for

DMC-1700

USER MANUAL

DMC-1700/1800

Manual Rev. 1.2m

By Galil Motion Control, Inc.

Galil Motion Control, Inc.

3750 Atherton Road

Rocklin, California 95765

Phone: (916) 626-0101

Fax: (916) 626-0102

Internet Address: [email protected]

URL: www.galilmc.com

Rev Date: 6/06

Using This Manual

This user manual provides information for proper operation of the DMC-1700 or DMC-1800

controller. The appendix to this manual contains information regarding the accessories to these

controllers. A separate supplemental manual, the Command Reference, contains a description of the

commands available for use with the controller.

Your motion controller has been designed to work with both servo and stepper type motors.

Installation and system setup will vary depending upon whether the controller will be used with

stepper motors or servo motors. To make finding the appropriate instructions faster and easier, icons

will be next to any information that applies exclusively to one type of system. Otherwise, assume that

the instructions apply to all types of systems. The icon legend is shown below.

Attention: Pertains to servo motor use.

Attention: Pertains to stepper motor use.

1X80

Attention: Pertains to controllers with more than 4 axes.

Please note that many examples are written for the DMC-1740 and DMC-1840 four-axes controller or

the DMC-1780 and DMC-1880 eight axes controller. Users of the DMC-1730/1830 3-axis controller,

DMC-1720/1820 2-axes controller, or DMC-1710/1810 1-axis controller should note that the DMC-

1730/1830 uses the axes denoted as XYZ, the DMC-1720/1820 uses the axes denoted as XY, and the

DMC-1710/1810 uses the X-axis only.

Examples for the DMC-1780/1880 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-

1750/1850 5-axes controller, DMC-1760/1860 6-axes controller, or DMC-1770/1870 7-axes controller

should note that the DMC-1750/1850 denotes the axes as A,B,C,D and E, the DMC-1760/1860 denotes

the axes as A,B,C,D,E and F, and the DMC-1770/1870 denotes the axes as A,B,C,D,E,F and G. The

axes A,B,C,D may be used interchangeably with X,Y,Z,W for any of the DMC1700 or DMC-1800

regardless of the number of axes.

This manual was written for the DMC-1700 firmware revision 1.1 and later and all DMC-1800

firmware revisions. For a DMC-1700 controller with firmware previous to revision 1.1, please consult

the original manual for your hardware.

17X8

Attention: Pertains to a DMC-1700 1 thru 4-axes controllers with an additional 64 I/O points.

WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design

effective error handling and safety protection as part of the machine. Galil shall not

be liable or

responsible for any incidental or consequential damages.

DMC-1700/1800 Contents • i

Contents

Contents i

Chapter 1 Overview 1

Introduction ...............................................................................................................................1

Overview of Motor Types..........................................................................................................2

Standard Servo Motor with +/- 10 Volt Command Signal ..........................................2

Brushless Servo Motor with Sinusoidal Commutation................................................ 2

Stepper Motor with Step and Direction Signals ..........................................................2

DMC-1700/1800 Functional Elements ......................................................................................2

Microcomputer Section ............................................................................................... 3

Motor Interface............................................................................................................ 3

Communication ...........................................................................................................3

General I/O..................................................................................................................3

System Elements .........................................................................................................4

Motor...........................................................................................................................4

Amplifier (Driver) .......................................................................................................4

Encoder........................................................................................................................4

Watch Dog Timer........................................................................................................5

Chapter 2 Getting Started 7

The DMC-17x0 and DMC-18x0 Motion Controllers................................................................7

Elements You Need ...................................................................................................................9

Installing the DMC-1700/1800................................................................................................10

Step 1. Determine Overall Motor Configuration.......................................................10

Step 2. Install Jumpers on the DMC-1700/1800........................................................11

Step 3. Install the Communications Software............................................................13

Step 4. Install the DMC-1700/1800 in the PC........................................................... 14

Step 5. Establishing Communication between the Galil controller and the host PC .14

Step 6. Determine the Axes to be Used for Sinusoidal Commutation.......................24

Step 7. Make Connections to Amplifier and Encoder. ..............................................25

Step 8a. Connect Standard Servo Motors.................................................................. 27

Step 8b. Connect Sinusoidal Commutation Motors...................................................31

Step 8C. Connect Step Motors .................................................................................. 33

Step 9. Tune the Servo System..................................................................................34

Design Examples ..................................................................................................................... 35

Example 1 - System Set-up ....................................................................................... 35

Example 2 - Profiled Move .......................................................................................35

Example 3 - Multiple Axes........................................................................................36

Example 4 - Independent Moves............................................................................... 36

Example 5 - Position Interrogation............................................................................ 36

ii • Contents DMC-1700/1800

Example 6 - Absolute Position .................................................................................. 37

Example 7 - Velocity Control....................................................................................37

Example 8 - Operation Under Torque Limit .............................................................37

Example 9 - Interrogation.......................................................................................... 38

Example 10 - Operation in the Buffer Mode ............................................................. 38

Example 11 - Using the On-Board Editor ................................................................. 38

Example 12 - Motion Programs with Loops..............................................................39

Example 13 - Motion Programs with Trippoints....................................................... 39

Example 14 - Control Variables ................................................................................39

Example 15 - Linear Interpolation.............................................................................40

Example 16 - Circular Interpolation.......................................................................... 40

Chapter 3 Connecting Hardware 43

Overview .................................................................................................................................43

Using Optoisolated Inputs ....................................................................................................... 43

Limit Switch Input.....................................................................................................43

Home Switch Input.................................................................................................... 44

Abort Input ................................................................................................................44

Uncommitted Digital Inputs ...................................................................................... 45

Wiring the Optoisolated Inputs................................................................................................45

Using an Isolated Power Supply................................................................................46

Bypassing the Opto-Isolation: ...................................................................................47

Analog Inputs ..........................................................................................................................47

Amplifier Interface ..................................................................................................................47

TTL Inputs...............................................................................................................................48

TTL Outputs ............................................................................................................................48

Chapter 4 - Software Tools and Communications 51

Introduction .............................................................................................................................51

Galil SmartTERM.................................................................................................................... 53

Communication Settings for ISA and PCI...............................................................................57

Windows Servo Design Kit (WSDK)......................................................................................61

Creating Custom Software Interfaces ......................................................................................62

DOS, Linux, and QNX tools....................................................................................................65

Controller Event Interrupts and User Interrupts ......................................................................65

Hardware Level Communications for ISA and PCI ................................................................ 67

Communications with the DMC-1700.......................................................................67

Communication with DMC-1700............................................................................... 68

Communication with DMC-1800............................................................................... 71

DMA / Secondary FIFO / DPRAM Memory Map ..................................................................73

Explanation of Status Information and Axis Switch Information..............................76

Chapter 5 Command Basics 79

Introduction .............................................................................................................................79

Command Syntax - ASCII.......................................................................................................79

Coordinated Motion with more than 1 axis ...............................................................80

Command Syntax - Binary ......................................................................................................80

Binary Command Format .......................................................................................... 81

Binary command table...............................................................................................82

Controller Response to DATA ................................................................................................83

Interrogating the Controller .....................................................................................................83

Interrogation Commands...........................................................................................83

Summary of Interrogation Commands ...................................................................... 83

Interrogating Current Commanded Values................................................................84

DMC-1700/1800 Contents • iii

Operands....................................................................................................................84

Command Summary..................................................................................................84

Chapter 6 Programming Motion 85

Overview .................................................................................................................................85

Independent Axis Positioning..................................................................................................87

Command Summary - Independent Axis ..................................................................87

Operand Summary - Independent Axis .....................................................................87

Independent Jogging................................................................................................................89

Command Summary - Jogging..................................................................................89

Operand Summary - Independent Axis .....................................................................90

Position Tracking.....................................................................................................................90

Example - Motion 2:.................................................................................................. 92

Example Motion 4 ..................................................................................................... 93

Trip Points ................................................................................................................. 94

Command Summary – Position Tracking Mode .......................................................95

Linear Interpolation Mode.......................................................................................................95

Specifying Linear Segments......................................................................................95

Command Summary - Linear Interpolation...............................................................97

Operand Summary - Linear Interpolation..................................................................97

Example - Linear Move............................................................................................. 98

Example - Multiple Moves........................................................................................99

Vector Mode: Linear and Circular Interpolation Motion.......................................................100

Specifying the Coordinate Plane ............................................................................. 100

Specifying Vector Segments ...................................................................................100

Additional commands.............................................................................................. 101

Command Summary - Coordinated Motion Sequence ............................................ 103

Operand Summary - Coordinated Motion Sequence...............................................103

Electronic Gearing................................................................................................................. 104

Ramped Gearing .................................................................................................................... 105

Example – Electronic Gearing Over a Specified Interval........................................ 106

Command Summary - Electronic Gearing ..............................................................107

Example - Simple Master Slave ..............................................................................107

Example - Electronic Gearing ................................................................................. 107

Example - Gantry Mode .......................................................................................... 107

Example - Synchronize two conveyor belts with trapezoidal velocity correction... 108

Electronic Cam ......................................................................................................................108

Command Summary - Electronic CAM ..................................................................111

Operand Summary - Electronic CAM ..................................................................... 112

Example - Electronic CAM..................................................................................... 112

Contour Mode........................................................................................................................ 113

Specifying Contour Segments ................................................................................. 113

Additional Commands............................................................................................. 114

Command Summary - Contour Mode .....................................................................115

Stepper Motor Operation .......................................................................................................119

Specifying Stepper Motor Operation.......................................................................119

Using an Encoder with Stepper Motors................................................................... 120

Command Summary - Stepper Motor Operation..................................................... 120

Operand Summary - Stepper Motor Operation........................................................120

Stepper Position Maintenance Mode (SPM).......................................................................... 121

Error Limit............................................................................................................... 121

Correction................................................................................................................ 122

Dual Loop (Auxiliary Encoder)............................................................................................. 125

Backlash Compensation .......................................................................................... 126

Motion Smoothing................................................................................................................. 127

iv • Contents DMC-1700/1800

Using the IT and VT Commands:............................................................................127

Using the KS Command (Step Motor Smoothing):................................................. 128

Homing .................................................................................................................................. 129

Stage 1:.................................................................................................................... 129

Stage 2:.................................................................................................................... 129

Stage 3:.................................................................................................................... 129

Command Summary - Homing Operation............................................................... 132

Operand Summary - Homing Operation..................................................................132

High Speed Position Capture (The Latch Function)..............................................................132

Fast Update Rate Mode .........................................................................................................133

Chapter 7 Application Programming 135

Overview ...............................................................................................................................135

Using the DMC-1700/1800 Editor to Enter Programs........................................................... 135

Edit Mode Commands............................................................................................. 136

Program Format..................................................................................................................... 136

Using Labels in Programs .......................................................................................136

Special Labels..........................................................................................................137

Commenting Programs............................................................................................ 137

Executing Programs - Multitasking ....................................................................................... 138

Debugging Programs .............................................................................................................139

Program Flow Commands ..................................................................................................... 140

Event Triggers & Trippoints....................................................................................141

Event Trigger Examples:.........................................................................................143

Conditional Jumps...................................................................................................145

Using If, Else, and Endif Commands ...................................................................... 147

Subroutines.............................................................................................................. 149

Stack Manipulation..................................................................................................149

Auto-Start Routine ..................................................................................................149

Automatic Subroutines for Monitoring Conditions................................................. 149

Mathematical and Functional Expressions ............................................................................153

Mathematical Operators .......................................................................................... 153

Bit-Wise Operators.................................................................................................. 153

Functions ................................................................................................................. 154

Variables................................................................................................................................155

Programmable Variables .........................................................................................155

Operands................................................................................................................................156

Special Operands (Keywords).................................................................................157

Arrays .................................................................................................................................... 157

Defining Arrays....................................................................................................... 157

Assignment of Array Entries ................................................................................... 158

Automatic Data Capture into Arrays....................................................................... 159

Deallocating Array Space........................................................................................ 160

Input of Data (Numeric and String).......................................................................................160

Input of Data............................................................................................................ 160

Output of Data (Numeric and String) .................................................................................... 161

Sending Messages ................................................................................................... 161

Displaying Variables and Arrays............................................................................. 163

Interrogation Commands.........................................................................................163

Formatting Variables and Array Elements .............................................................. 165

Converting to User Units......................................................................................... 165

Hardware I/O .........................................................................................................................166

Digital Outputs ........................................................................................................166

Digital Inputs...........................................................................................................167

Input Interrupt Function ..........................................................................................167

DMC-1700/1800 Contents • v

Analog Inputs .......................................................................................................... 168

Example Applications............................................................................................................169

Wire Cutter.............................................................................................................. 169

X-Y Table Controller ..............................................................................................170

Speed Control by Joystick....................................................................................... 172

Position Control by Joystick.................................................................................... 174

Backlash Compensation by Sampled Dual-Loop ....................................................174

Chapter 8 Hardware & Software Protection 177

Introduction ...........................................................................................................................177

Hardware Protection .............................................................................................................. 177

Output Protection Lines........................................................................................... 177

Input Protection Lines .............................................................................................177

Software Protection ...............................................................................................................178

Programmable Position Limits ................................................................................ 178

Off-On-Error ........................................................................................................... 179

Automatic Error Routine ......................................................................................... 179

Limit Switch Routine .............................................................................................. 179

Chapter 9 Troubleshooting 181

Overview ...............................................................................................................................181

Installation .............................................................................................................................181

Communication......................................................................................................................182

Stability.................................................................................................................................. 182

Operation ...............................................................................................................................183

Chapter 10 Theory of Operation 185

Overview ...............................................................................................................................185

Operation of Closed-Loop Systems....................................................................................... 187

System Modeling................................................................................................................... 188

Motor-Amplifier...................................................................................................... 189

Encoder....................................................................................................................191

DAC ........................................................................................................................ 192

Digital Filter ............................................................................................................192

ZOH.........................................................................................................................193

System Analysis.....................................................................................................................193

System Design and Compensation.........................................................................................195

The Analytical Method............................................................................................ 195

Appendices 199

Electrical Specifications ........................................................................................................199

Servo Control .......................................................................................................... 199

Stepper Control........................................................................................................ 199

Input/Output ............................................................................................................199

Power....................................................................................................................... 200

Performance Specifications ................................................................................................... 200

Connectors for DMC-1700/1800 Main Board ....................................................................... 201

Pin-Out Description for DMC-1700/1800 ............................................................................. 203

Setting Addresses for the DMC-1700.................................................................................... 206

Standard Addresses ................................................................................................. 206

Plug and Play Addresses .........................................................................................209

Accessories and Options........................................................................................................210

PC/AT Interrupts and Their Vectors...................................................................................... 211

vi • Contents DMC-1700/1800

ICM-1900 Interconnect Module ............................................................................................ 211

ICM-1900 Drawing ...............................................................................................................215

AMP-19X0 Mating Power Amplifiers................................................................................... 215

ICM-2900 Interconnect Module ............................................................................................ 216

Opto-Isolated Outputs ICM-1900 / ICM-2900 (-Opto option) .............................................. 219

Standard Opto-isolation and High Current Opto-isolation:.....................................219

64 Extended I/O of the DMC-17x8/1700/1800 Controller....................................................219

Configuring the I/O of the DMC-17x8 (and DMC-1750 to DMC-1780 & DMC-

1810 to 1880, with DB-14064)................................................................................

219

Configuring the 64 Extended I/O of the DMC-1750 to 1780 and 1850 to 1880 using

the DB-14064 ..........................................................................................................

221

Connector Description:............................................................................................ 221

IOM-1964 Opto-Isolation Module for Extended I/O Controllers.......................................... 224

Description: .............................................................................................................224

Overview ................................................................................................................. 225

Configuring Hardware Banks..................................................................................226

Digital Inputs...........................................................................................................227

High Power Digital Outputs .................................................................................... 229

Standard Digital Outputs ......................................................................................... 230

Electrical Specifications ..........................................................................................231

Relevant DMC Commands...................................................................................... 232

Screw Terminal Listing ........................................................................................... 232

Coordinated Motion - Mathematical Analysis....................................................................... 234

DMC-1700/DMC-1000 Comparison..................................................................................... 237

List of Other Publications...................................................................................................... 238

Training Seminars.................................................................................................................. 239

Contacting Us ........................................................................................................................240

WARRANTY ........................................................................................................................ 240

Index 241

DMC-1700/1800 Chapter 1 Overview • 1

Chapter 1 Overview

Introduction

The DMC-1700 series motion control cards install directly into the ISA bus while the DMC-1800 series motion

controllers install directly into a PCI slot. These controller series offers many enhanced features including high-

speed communications, non-volatile program memory, faster encoder speeds, and improved cabling for EMI

reduction.

The DMC-1700/1800 provides two channels for high speed communication. Both controllers use a high speed main

FIFO for sending and receiving commands. Additionally, the DMC-1700 provides a DMA channel which places a

data record directly into PC memory or a secondary polling FIFO for instant access to controller status and

parameters. The DMC-1800 provides either Dual Port RAM (DPRAM) or a secondary polling FIFO for instant

access to controller status and parameters. The controllers allow for high-speed servo control up to 12 million

encoder counts/sec and step motor control up to 3 million steps per second. Sample rates as low as 62.5μsec per

axis are available.

A 4 meg Flash EEPROM provides non-volatile memory for storing application programs, parameters, arrays, and

firmware. New firmware revisions are easily upgraded in the field without removing the controller from the PC.

The DMC-1700 is available with up to eight axes on a single ISA card. The DMC-1710, 1720, 1730, 1740 one thru

four axes controllers are on a single 10.25” x 4.8” card and the DMC-1750, 1760, 1770, 1780 five thru eight axes

controllers are on a single 13.25” x 4.8” card.

The DMC-1800 is available from one to eight axes on a single PCI card. The DMC-1810, 1820, 1830, 1840,

covering from one to four axes, are on a single 8.2” x 4.2” card and the DMC-1850, 1860, 1870, 1880 five thru eight

axes controllers are on a single 12.28” x 4.2” card.

Designed to solve complex motion problems, the DMC-1700/1800 can be used for applications involving jogging,

point-to-point positioning, vector positioning, electronic gearing, multiple move sequences and contouring. The

controller eliminates jerk by programmable acceleration and deceleration with profile smoothing. For smooth

following of complex contours, the DMC-1700/1800 provides continuous vector feed of an infinite number of linear

and arc segments. The controller also features electronic gearing with multiple master axes as well as gantry mode

operation.

For synchronization with outside events, the DMC-1700 and DMC-1800 provide uncommitted I/O, including 8

digital inputs (24 inputs for DMC-1750 thru DMC-1780 and DMC-1850 thru DMC-1880), 8 digital outputs (16

outputs for DMC-1750 thru DMC-1780 and DMC-1850 thru DMC-1880), and 8 analog inputs for interface to

joysticks, sensors, and pressure transducers. The DMC-1718, 1728, 1738, and 1748 controllers are also available

for an additional 64 I/O. Dedicated optoisolated inputs are provided on all DMC-1700/1800 controllers for forward

and reverse limits, abort, home, and definable input interrupts. The DMC-1800 has plug and play capabilities to ease

the setup process. Commands can be sent in either Binary or ASCII. Additional software is available to autotune,

view trajectories on a PC screen, translate CAD.DXF files into motion, and create powerful, application-specific

operator interfaces with Visual Basic. Drivers for WIN98SE, ME, NT4.0, 2000 and XP are available.

2 • Chapter 1 Overview DMC-1700/1800

Overview of Motor Types

The DMC-1700/1800 can provide the following types of motor control:

1. Standard servo motors with +/- 10 volt command signals

2. Brushless servo motors with sinusoidal commutation

3. Step motors with step and direction signals

4. Other actuators such as hydraulics - For more information, contact Galil.

The user can configure each axis for any combination of motor types, providing maximum flexibility.

Standard Servo Motor with +/- 10 Volt Command Signal

The DMC-1700/1800 achieves superior precision through use of a 16-bit motor command output DAC and a

sophisticated PID filter that features velocity and acceleration feedforward, an extra pole filter, and integration

limits.

The controller is configured by the factory for standard servo motor operation. In this configuration, the controller

provides an analog signal (+/- 10Volt) to connect to a servo amplifier. This connection is described in Chapter 2.

Brushless Servo Motor with Sinusoidal Commutation

The DMC-1700/1800 can provide sinusoidal commutation for brushless motors (BLM). In this configuration, the

controller generates two sinusoidal signals for connection with amplifiers specifically designed for this purpose.

Note: The task of generating sinusoidal commutation may be accomplished in the brushless motor amplifier. If the

amplifier generates the sinusoidal commutation signals, only a single command signal is required and the controller

should be configured for a standard servo motor (described above).

Sinusoidal commutation in the controller can be used with linear and rotary BLMs. However, the motor velocity

should be limited such that a magnetic cycle lasts at least 6 milliseconds*. For faster motors, please contact the

factory.

To simplify the wiring, the controller provides a one-time, automatic set-up procedure. The parameters determined

by this procedure can then be saved in non-volatile memory to be used whenever the system is powered on.

The DMC-1700/1800 can control BLMs equipped with or without Hall sensors. If hall sensors are available, once

the controller has been setup, the controller will automatically estimates the commutation phase upon reset. This

allows the motor to function immediately upon power up. The hall effect sensors also provides a method for setting

the precise commutation phase. Chapter 2 describes the proper connection and procedure for using sinusoidal

commutation of brushless motors.

* 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec (default rate).

Stepper Motor with Step and Direction Signals

The DMC-1700/1800 can control stepper motors. In this mode, the controller provides two signals to connect to the

stepper motor: Step and Direction. For stepper motor operation, the controller does not require an encoder and

operates the stepper motor in an open loop fashion. Chapter 2 describes the proper connection and procedure for

using stepper motors.

DMC-1700/1800 Functional Elements

The DMC-1700/1800 circuitry can be divided into the following functional groups as shown in Figure 1.1 and

discussed below.

DMC-1700/1800 Chapter 1 Overview • 3

WATCHDOG TIMER

68331

MICROCOMPUTER

WITH

4 Meg RAM

4 Meg FLASH EEPROM

HIGH-SPEED

MOTOR/ENCODER

INTERFACE

FOR

X,Y,Z,W, etc.

I/O INTERFACE

DMA/DPRAM

2ND FIFO

Primary

FIFOS

ISA/PCI BUS

8 UNCOMMITTED

ANALOG INPUTS

HIGH-SPEED LATCH FOR EACH AXIS

8 PROGRAMMABLE,

OPTOISOLATED

INPUTS

8 PROGRAMMABLE

OUTPUTS

ISOLATED LIMITS AND

HOME INPUTS

MAIN ENCODERS

AUXILIARY ENCODERS

+/- 10 VOLT OUTPUT FOR

SERVO MOTORS

PULSE/DIRECTION OUTPUT

FOR STEP MOTORS

HIGH SPEED ENCODER

COMPARE OUTPUT

Interrupts

Figure 1.1 - DMC-1700/1800 Functional Elements

Microcomputer Section

The main processing unit of the controller is a specialized 32-bit Motorola 68331 Series Microcomputer with 512K

byte RAM and 512K byte Flash EEPROM. The RAM provides memory for variables, array elements, and

application programs. The flash EEPROM provides non-volatile storage of variables, programs, and arrays. The

Flash also contains the firmware of the controller, which is field upgradeable.

Motor Interface

Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at up to 12 MHz.

For standard servo operation, the controller generates a +/-10 Volt analog signal (16 Bit DAC). For sinusoidal

commutation operation, the controller uses 2 DACs to generate 2

+/-10Volt analog signals. For stepper motor

operation the controller generates a step and direction signal.

Communication

The communication interface with the host PC contains a primary and secondary communication channel. The

primary channel uses a bi-directional FIFO and includes PC interrupt handling circuitry. The secondary channel can

be set as DMA or DPRAM where data is placed in PC memory or as a Polling FIFO where data is placed into the

controller’s FIFO buffer. The DMA is available on the DMC-1700 and, DPRAM is only available on the DMC-

1800 (1810-1840 Rev H and greater, DMC-1850-1880 Rev E and greater), whereas the Polling FIFO is available on

both the DMC-1700 and DMC-1800.

General I/O

The controller provides interface circuitry for 8 bi-directional, optoisolated inputs, 8 TTL outputs, and 8 analog

inputs with 12-Bit ADC (16-bit optional). The general inputs can also be used for triggering a high-speed positional

latch for each axis.

Each axis on the controller has 2 encoders, the main encoder and an auxiliary encoder. Each unused auxiliary

encoder provides 2 additional inputs available for general use (except when configured for stepper motor operation).

4 • Chapter 1 Overview DMC-1700/1800

17X8

The DMC-1718, 1728, 1738, 1748 controllers have 64 additional general I/O points. The user can

configure these I/O points as inputs or outputs in blocks of 8.

1X80

The DMC-1750 through DMC-1780 and DMC-1850 through DMC-1880 controllers provide interface

circuitry for 16 optoisolated inputs, 8 TTL inputs, 16 TTL outputs, and 8 analog inputs with 12-bit

ADC (16-bit optional).

System Elements

As shown in Fig. 1.2, the DMC-1700/1800 is part of a motion control system which includes amplifiers, motors, and

encoders. These elements are described below.

Computer

DMC-1700/1800

Controller

Driver

Power Supply

Encoder Motor

Figure 1.2 - Elements of Servo systems

Motor

A motor converts current into torque, which produces motion. Each axis of motion requires a motor sized properly

to move the load at the required speed and acceleration. (Galil’s “Motion Component Selector” software can help

you with motor sizing). Download at

www.galilmc.com/support/download, select “MCS”.

The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step motors, the

controller can operate full-step, half-step, or microstep drives. An encoder is not required when step motors are

used.

Amplifier (Driver)

For each axis, the power amplifier converts a +/-10 Volt signal from the controller into current to drive the motor.

For stepper motors, the amplifier converts step and direction signals into current. The amplifier should be sized

properly to meet the power requirements of the motor. For brushless motors, an amplifier that provides electronic

commutation is required or the controller must be configured to provide sinusoidal commutation. The amplifiers

may be either pulse-width-modulated (PWM) or linear. They may also be configured for operation with or without

a tachometer. For current amplifiers, the amplifier gain should be set such that a 10 Volt command generates the

maximum required current. For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V. For

velocity mode amplifiers, 10 Volts should run the motor at the maximum speed.

Encoder

An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-1700/1800

accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels in quadrature,

known as CHA and CHB. This type of encoder is known as a quadrature encoder. Quadrature encoders may be

DMC-1700/1800 Chapter 1 Overview • 5

either single-ended (CHA and CHB) or differential (CHA, CHA-, CHB, CHB-). The controller decodes either type

into quadrature states or four times the number of cycles. Encoders may also have a third channel (or index) for

synchronization.

The DMC-1700/1800 can also interface to encoders with pulse and direction signals. Refer to the “CE” command in

the command reference for details.

There is no limit on encoder line density; however, the input frequency to the controller must not exceed 3,000,000

full encoder cycles/second (12,000,000 quadrature counts/sec). For example, if the encoder line density is 10,000

cycles per inch, the maximum speed is 300 inches/second. If higher encoder frequency is required, please consult

the factory.

The standard encoder voltage level is TTL (0-5v), however, voltage levels up to 12 Volts are acceptable. (If using

differential signals, 12 Volts can be input directly to the DMC-1700/1800. Single-ended 12 Volt signals require a

bias voltage input to the complementary inputs).

The DMC-1700/1800 can accept analog feedback (+/-10v) instead of an encoder for any axis. For more information

see the command AF in the command reference.

To interface with other types of position sensors such as absolute encoders, Galil can customize the controller and

command set. Please contact Galil to talk to one of our applications engineers about your particular system

requirements.

Watch Dog Timer

The DMC-1700/1800 provides an internal watchdog timer which checks for proper microprocessor operation. The

timer toggles the Amplifier Enable Output (AEN), which can be used to switch the amplifiers off in the event of a

serious controller failure. The AEN output is normally high. During power-up and if the microprocessor ceases to

function properly, the AEN output will go low. The error light for each axis will also turn on at this stage. A reset

is required to restore the controller to normal operation. Consult the factory for a Return Materials Authorization

(RMA) Number if your DMC-1700/1800 is damaged.

6 • Chapter 1 Overview DMC-1700/1800

THIS PAGE LEFT BLANK INTENTIONALLY

DMC-1700/1800 Chapter 2 Getting Started • 7

Chapter 2 Getting Started

The DMC-17x0 and DMC-18x0 Motion Controllers

JP8

JP5

JP4

JP9

JP3

JP1

Figure 2-1 - Outline of the DMC-1710 through DMC-1740

JP1

JP8

JP9

JP6

JP5

JP3

JP4

Figure 2-2 - Outline of the DMC-1750 through DMC-1780

8 • Chapter 2 Getting Started DMC-1700/1800

Figure 2-3 - Outline of the DMC-1810 through DMC-1840

Figure 2-4 - Outline of the DMC-1850 through DMC-1880

1 Flash EEPROM J8

50-pin header connector corresponding to pins 1

through 50 of connector for axes 5-8

2 RAM JP1 Master Reset & UPGRD jumpers

3 Motorola 68331 microprocessor JP3

INCOM & LSCOM jumpers. Used for bypassing opto-

isolation for the limit, home, and abort switches and the

digital inputs IN1 - IN8. See section “Bypassing Opto-

Isolation”, Chap3.

DMC-1850/1880 – 1 thru 4 axis only

DMC-1700/1800 Chapter 2 Getting Started • 9

4 Galil GL-1800 custom gate array JP4

Jumpers used for configuring stepper motor operation

on axes 5-8 (DMC-1750/1780 and DMC-1850/1880

only).

Jumpers used to select DMA channel 0 or 1 (DMC-

1710/1740 only).

5 Error LED JP5

Jumpers used for configuring stepper motor operation

on axes 1-4.

6 Xilinx for PCI bus communications JP6

Jumpers used to select DMA channel 0 or 1 (DMC-

1780 only).

J1 100-pin high density connector for axes 1-4.

(Part number Amp #2-178238-9)

JP8 Address jumpers A2 – A8

26-pin header connector for the auxiliary encoder

cable. (Axes 1-4)

JP9 IRQ jumper.

J6 / J8

Two 50-pin headers connecting corresponding

signals for axes 5-8

JP13

INCOM & LSCOM jumpers. Used for bypassing opto-

isolation for the limit, home, and abort switches and the

digital inputs IN9 – IN16. See section “Bypassing

Opto-Isolation”, Chap3. (DMC-1850/1880 only)

26-pin header connector for the auxiliary encoder

cable. (Axes 5-8)

Note: Above layouts are for the most current controller revisions. For older revision boards, please

refer to Appendix.

Elements You Need

Before you start, you must get all the necessary system elements. These include:

1a. DMC-1710/1810, 1720/1820, 1730/1830, or DMC-1740/1840 Motion Controller, (1)

100-pin cable, and (1) ICM-1900 interconnect module.

1b. DMC-1750/1850, 1760/1860, 1770/1870 or DMC-1780/1880, (2) 100-pin cables and (2)

ICM-1900s. CB 50-100 connector board and included two 50-pin ribbon cables which

converts the two 50-pin ribbon cables into a single 100-pin connector.

1c. DMC-1718, 1728, 1738, 1748, (1) 100-pin cables and (1) ICM-1900s. Connection to the

extended I/O can be made through the IOM-1964 opto-isolation module. Using the IOM-

1964 requires (1) IOM-1964, (1) CB-50-100 and (1) 100 pin cable.

2. Servo motors with Optical Encoder (one per axis) or step motors.

3. Power Amplifiers.

4. Power Supply for Amplifiers.

5. PC (Personal Computer - ISA bus or PCI bus).

6. Galil SmartTerm (from CD ROM or download at www.galilmc.com)

7. WSDK is optional but recommended for first time users.

The motors may be servo (brush type or brushless) or steppers. The amplifiers should be suitable for the motor and

may be linear or pulse-width-modulated. An amplifier may have current feedback, voltage feedback or velocity

feedback

10 • Chapter 2 Getting Started DMC-1700/1800

For servo motors in current mode, the amplifiers should accept an analog signal in the +/-10 Volt range

as a command. The amplifier gain should be set such that a +10V command will generate the

maximum required current. For example, if the motor peak current is 10A, the amplifier gain should

be 1 A/V. For velocity mode amplifiers, a command signal of 10 Volts should run the motor at the

maximum required speed. Set the velocity gain so that an input signal of 10V, runs the motor at the

maximum required speed.

For step motors, the amplifiers should accept step and direction signals. For start-up of a step motor

system refer to Step 8c “Connecting Step Motors”.

The WSDK software is highly recommended for first time users of the DMC-1700/1800. It provides step-by-step

instructions for system connection, tuning and analysis.

Installing the DMC-1700/1800

Installation of a complete, operational DMC-1700/1800 system consists of 9 steps.

Step 1. Determine overall motor configuration.

Step 2. Install Jumpers on the DMC-1700/1800.

Step 3. Install the communications software.

Step 4. Install the DMC-1700/1800 in the PC.

Step 5. Establish communications with the Galil Communication Software.

Step 6. Determine the Axes to be used for sinusoidal commutation.

Step 7. Make connections to amplifier and encoder.

Step 8a. Connect standard servo motors.

Step 8b. Connect sinusoidal commutation motors

Step 8c. Connect step motors.

Step 9. Tune the servo system

Step 1. Determine Overall Motor Configuration

Before setting up the motion control system, the user must determine the desired motor configuration. The DMC-

1700/1800 can control any combination of standard servo motors, sinusoidally commutated brushless motors, and

stepper motors. Other types of actuators, such as hydraulics can also be controlled, please consult Galil.

The following configuration information is necessary to determine the proper motor configuration:

Standard Servo Motor Operation:

The DMC-1700/1800 has been setup by the factory for standard servo motor operation providing an analog

command signal of +/- 10V. No hardware or software configuration is required for standard servo motor operation.

Sinusoidal Commutation:

Sinusoidal commutation is configured through a single software command, BA. This configuration causes the

controller to reconfigure the number of available control axes.

Each sinusoidally commutated motor requires two DAC’s. In standard servo operation, the DMC-1700/1800 has

one DAC per axis. In order to have the additional DAC for sinusoidal commutation, the controller must be

designated as having one additional axis for each sinusoidal commutation axis. For example, to control two

DMC-1700/1800 Chapter 2 Getting Started • 11

standard servo axes and one axis of sinusoidal commutation, the controller will require a total of four DAC’s and the

controller must be a DMC-1740 or DMC-1840.

Sinusoidal commutation is configured with the command, BA. For example, BAX sets the X axis to be sinusoidally

commutated. The second DAC for the sinusoidal signal will be the highest available DAC on the controller. For

example: Using a DMC-1740, the command BAX will configure the X axis to be the main sinusoidal signal and the

‘W’ axis to be the second sinusoidal signal.

The BA command also reconfigures the controller to indicate that the controller has one less axis of ‘standard’

control for each axis of sinusoidal commutation. For example, if the command BAX is given to a DMC-1740

controller, the controller will be re-configured to a DMC-1730 controller. By definition, a DMC-1730 controls 3

axes: X,Y and Z. The ‘W’ axis is no longer available since the output DAC is being used for sinusoidal

commutation.

Further instruction for sinusoidal commutation connections are discussed in Step 6.

Stepper Motor Operation:

To configure the DMC-1700/1800 for stepper motor operation, the controller requires a jumper for each stepper

motor and the command, MT, must be given. The installation of the stepper motor jumper is discussed in the

following section entitled “Installing Jumpers on the DMC-1700/1800”. Further instruction for stepper motor

connections are discussed in Step 8c.

Step 2. Install Jumpers on the DMC-1700/1800

Master Reset and Upgrade Jumpers

JP1 contains two jumpers, MRST and UPGRD. The MRST jumper is the Master Reset jumper. With

MRST connected, the controller will perform a master reset upon PC power up or upon the reset input

going low. Whenever the controller has a master reset, all programs, arrays, variables, and motion

control parameters stored in EEPROM will be ERASED.

The UPGRD jumper enables the user to unconditionally update the controller’s firmware. This jumper

is not necessary for firmware updates when the controller is operating normally, but may be necessary

in cases of corrupted EEPROM. EEPROM corruption should never occur, however, it is possible if

there is a power fault during a firmware update. If EEPROM corruption occurs, your controller may

not operate properly. In this case, install the UPGRD Jumper and use the update firmware function on

the Galil Terminal to re-load the system firmware.

Opto Isolation Jumpers

The inputs and limit switches are optoisolated. If you are not using an isolated supply, the internal

+5V supply from the PC may be used to power the optoisolators. This is done by installing jumpers on

JP3 and/or JP13.

Stepper Motor Jumpers

For each axis that will be used for stepper motor operation, the corresponding stepper mode (SM)

jumper must be connected. The stepper motor jumpers, labeled JP5 for axes X through W and JP4 for

axes E through H, are located directly beside the GL-1800 IC’s on the main board (see the diagram for

the DMC-1700/1800). The individual jumpers are labeled SMX, SMY, SMZ and SMW for axes 1

through 4 and SME, SMF, SMG and SMH for axes 5 through 8.

(Optional) DMA Jumpers

The DMA channel is only available with the DMC-1700 controller. The DMC-1700 controller allows

either DMA channel 0 or 1 to be selected. The jumper location JP4 on the DMC-1740 and JP6 on the

12 • Chapter 2 Getting Started DMC-1700/1800

DMC-1780 allows the user to select which channel will be used. The DMA channel chosen should be

reflected within the Galil software registry. 2.5 illustrates these settings.

Please note earlier controller revisions (Rev. E and earlier for DMC-1740, Rev. C and earlier for

DMC-1780) did not have hardware jumpers for DMA channel selection.

DAC

Setting for DMA channel 1 Setting for DMA channel 0

1 0

Figure 2.5 - Jumper settings for DMC-1700 DMA

(Optional) IRQ (Interrupt) Jumpers

IRQ jumpers are not necessary for communication with the Galil controllers. Rather, they are an

option that may be used for notifying the PC of events that occur on the motion controller. The

selectable IRQ jumpers are only available on the DMC-1700. The PCI drivers for the DMC-1800 will

automatically assign it an IRQ based on system availability.

On the DMC-1700, select which IRQ line will be used when the controller needs to notify the PC of an

interrupt. You will need to select an IRQ line which is open on your PC, meaning not shared with any

other device. Within the Galil Software Registry, the corresponding IRQ line should be entered into

the controller registry information.

NOTE: For Version 7 Drivers and ISA/PC-104 controllers with new firmware, a jumper MUST

be installed on one of the IRQ jumper pins in order to use Interrupt Communication (the default

method of communication). Match the IRQ jumper on the board with an IRQ Setting that

displays “No Conflicts” in the Device Manager.

If No IRQ lines are available or Interrupt Communication is not desired, the user must go to the

“Controller Registration” menu and uncheck the “Interrupt Communication” method. Stall or

Delay methods of communication will then be used. A Communication Timeout error will occur

if this is not done.

(Optional) Motor Off Jumpers

The state of the motor upon power up may be selected with the placement of a hardware jumper on the

controller. With a jumper installed at the MO location, the controller will be powered up in the ‘motor

off’ state. The SH command will need to be issued in order for the motor to be enabled. With no

jumper installed, the controller will immediately enable the motor upon power up. The MO command

will need to be issued to turn the motor off.

The MO jumper is always located on the same block of jumpers as the stepper motor jumpers (SM).

This feature is only available to newer revision controllers (Rev. F and later for DMC-1740, Rev. D

and later for DMC-1780, Rev. C and later for DMC-1840). Please consult Galil for adding this

functionality to older revision controllers.

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Galil DMC-1800 User manual

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Model: DMC-1800

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